Implementation of Statistical Process Control through PDCA Cycle to Improve Potential Capability Index of Drop Impact Resistance: A Case Study at Aluminum Beverage and Beer Cans Manufacturing Industry in Indonesia

Sunadi, Sunadi; Purba, Humiras Hardi; Hasibuan, Sawarni

doi:10.12776/qip.v24i1.1401

Cited by 19 publications

(18 citation statements)

References 14 publications

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“…Several problem-solving tools, such as PDCA (Plan, Do, Check, Action) and DMAIC (Define-Measure-Analyze-Improve-Control), are widely used today. PDCA is a traditional approach used to solve medium-scale problems and implies that the PDCA cycle must be restarted in the Act phase to ensure continuous improvement, as in (Sunadi, Purba and Hasibuan, 2020) which uses the PDCA method to increase the process capability. In concept, however, the PDCA can still be enhanced again, so that the process's ability can even be better.…”

Section: Literature Reviewmentioning

confidence: 99%

Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

Setiawan

Hasibuan

2021

QIP Journal

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Purpose: The research aims to design a performance improvement framework for a new model of sports shoes to increase the ramp-up process time. Methodology/Approach: The approach used the problem-solving system of 8 disciplines, Single Minute Exchange Dies, Visual Management, and the Just In Time principle. Findings: By using the methods described above, the research findings will have a positive impact on the company. Model changeover time was reduced from 600 minutes to 102 minutes, and ramp-up time was reduced from 20 days to 2 days. Research Limitation/Implication: The limitation of this study was that only the CK2946 model was still done as a case study. The cost and other inhibiting factors were also not included in the discussion of this rump-up process. Originality/Value of paper: By integrating SMED, Just In Time, visual management, and using 8-Dicipline, the researcher developed a framework for improved performance for ramping up a new model of sports shoes.

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Section: Literature Reviewmentioning

confidence: 99%

Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

Setiawan

Hasibuan

2021

QIP Journal

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“…They analyzed and found out the solutions for the process capability index meeting the specification. The results showed that PDCA is a useful and effective method for improving packaging quality [15]. The benefits of practicing PDCA in planning, testing, and developing changes for target purposes make it become a well-known technique in the quality management field [16][17][18][19].…”

Section: Literature Reviewmentioning

confidence: 99%

Practical Application of Plan–Do–Check–Act Cycle for Quality Improvement of Sustainable Packaging: A Case Study

Nguyen

Schumacher

et al. 2020

Applied Sciences

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The research aims to give practical instructions for applying Plan–Do–Check–Act (PDCA) cycle in a packaging process. Eco-friendly, recycled material and a new packaging method for quality improvement and cost efficiency of heavily fragile product packaging are studied in this paper. A case study was conducted at GPEM laboratory, Vietnamese German University, Vietnam. In this case study, the current packaging style with Styrofoam material was analyzed and replaced by new packaging material and methods after applying the PDCA cycle for continuous quality improvement. Targets of the research were to find the new packaging method using friendly environment materials, to improve the quality, and to reduce the defect ratio due to packaging for fine-stone round surface fountains. Moreover, the extra cost should not be higher than 20% compared with the current packaging cost. The article proposes a simplified way that focuses on the combination of quality tools in the PDCA multiple phases to solve these problems. The quality tools are applied effectively through the PDCA cycle from collecting data, defining, analysis, testing, evaluation, and making decisions. New packaging design was been produced and tested successfully. One hundred percent of new packaging boxes for the mid-weight fountains (under 15 kg) passed the dropping test condition. Nearly 10% of the heavier weight products (above 15 kg) still had some small cracks on their top and bottom due to drop tests. Another PDCA cycle is recommended to continue applying for achieving a thorough solution. The conducted results show that PDCA is an effective method to tackle the damage product issue due to inappropriate packaging material and technique. It also brings good solutions for balancing sustainable packaging improvement and reducing the cost to ensure profit for companies. Besides contributing a guide reference for PDCA deployment, the authors intend to inspire practitioners and researchers to broaden exploration of the PDCA applications for sustainable packaging methodology. The research analysis shows that the PDCA methodology should be applied for defect reduction and quality enhancement in the packaging field. The field currently lacks systematic guidance for continuous improvement.

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“…With the consideration of increasingly rapid evolution, organizations must compete with strict attention to the factors that affect the process. Therefore, companies must continue to pay attention to the delivery time limit, costs to be incurred, and the quality of their products so that they are in line with market demand [6]. Quality management methods are successfully used in business process development and need to be continuously improved in terms of adapting business models so that companies become more competitive [7].…”

Section: Introductionmentioning

confidence: 99%

Analysis and Defect Improvement Using FTA, FMEA, and MLR Through DMAIC Phase: Case Study in Mixing Process Tire Manufacturing Industry

Febriana¹,

Hasbullah²

2021

JESA

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In line with the increasingly fierce industry competition, all companies strive to make continuous improvements to increase added value and reduce waste which will impact the company's ability to maintain its existence in the future. One of the problems found in the tire manufacturing industry is the quality problem of the occurrence of defects in the mixing process which is dominated by the viscosity out standard on the compound steel breaker. In this study, analysis and improvement of the defect problem were carried out using Fault Tree Analysis (FTA), Failure Mode and Effect Analysis (FMEA), and Multiple Linear Regression (MLR) to test the correlation between the root causes found to the main problem. Based on the results of the analysis found thirteen root causes where the factor of variation in material viscosity and the suitability of determining the design process has the largest Risk Priority Number (RPN) value and has a strong correlation to defects that occur based on hypothesis testing. Furthermore, improvements are made using the DMAIC method on all factors that affect the occurrence of defects. As the result, the improvement can be effective in reducing the defect to 34.5% and achieve the expected target.

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Implementation of Statistical Process Control through PDCA Cycle to Improve Potential Capability Index of Drop Impact Resistance: A Case Study at Aluminum Beverage and Beer Cans Manufacturing Industry in Indonesia

Cited by 19 publications

References 14 publications

Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

Practical Application of Plan–Do–Check–Act Cycle for Quality Improvement of Sustainable Packaging: A Case Study

Analysis and Defect Improvement Using FTA, FMEA, and MLR Through DMAIC Phase: Case Study in Mixing Process Tire Manufacturing Industry

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